Trends in Manufacturing Processes (eBook)

Preface 6
Contents 7
About the Editors 9
1 Optimization-Related Studies on the Operational Parameters of Friction Stir Welding: An Overview 11
1.1 Introduction 11
1.2 Review Related to Experimental and Theoretical Studies of FSW 12
1.3 Review Related to Optimization Studies of FSW 14
1.4 Conclusion 17
References 17
2 Experimental and Numerical Procedure for Studying Effect of Ultrasonic Spot Weld Parameters on Metal Joints for Electronic Components 20
2.1 Introduction 21
2.2 Methodology 22
2.2.1 Experimental Setup 22
2.2.2 Design of Experiments 22
2.3 Finite-Element Modelling (FEM) 23
2.4 Results and Discussions 25
2.4.1 Mechanical Properties Evaluation of Copper/Brass Weld Region 25
2.4.2 Scanning Electron Microscope (SEM) 26
2.4.3 Heat Conduction from the Copper/Brass Weld Zone 28
2.5 Conclusions 28
References 30
3 Micro-Electrical Discharge Machining for Machining Micro-Holes 32
3.1 Introduction 32
3.2 Experimental Setup and Method 34
3.2.1 Experimental Setup 34
3.2.2 Machining Electrode Tool and Workpiece 34
3.2.3 Experimental Method for Micro-Hole Drilling 36
3.2.4 Experimental Design and Analysis 37
3.3 Results and Discussion 38
3.3.1 Effect of Process Parameters on MRR 39
3.3.2 Effect of Process Parameters on TWR 40
3.3.3 Analysis of Variance (ANOVA) 42
3.4 Conclusion 42
References 43
4 Nd:YVO4 Laser Welding of Two Transparent Polymers in Lap Joint Configuration 44
4.1 Introduction 44
4.2 Experimental Setup and Procedure 45
4.3 Results and Discussions 47
4.3.1 Analysis-of-Variance 47
4.3.2 Impact of Input Welding Parameters on Ultimate Load 50
4.4 Confirmatory Test 51
4.5 Conclusions 52
References 52
5 Thermo-Mechanical Modeling of Friction Stir Welding of High Strength Aluminum Alloy 7075 T651 53
5.1 Introduction 53
5.2 Modeling Description and Boundary Condition 54
5.3 Results and Discussion 57
5.4 Conclusions 60
References 60
6 Full-Factorial Design Approach to Parametric Optimization and Modeling of Car Suspension System 61
6.1 Introduction 61
6.2 Design of Experiments 62
6.2.1 Sensitivity Analysis 63
6.2.2 Response Optimizer 63
6.3 Test Validation 65
6.4 Conclusion 66
References 66
7 Green-Machining Characteristics Study and Comparison in Meso-Scale End-Milling of AISI-1055 and AISI-4340 Steels 68
7.1 Introduction 69
7.2 Experimental 69
7.2.1 Experimental Design 70
7.2.2 Surface Roughness and Burr Width Measurement 72
7.3 Results and Discussions 72
7.3.1 Average Surface Roughness 73
7.3.2 Burr Width 74
7.3.3 Regression Modelling 74
7.4 Comparison Between AISI-1055 and AISI-4340 Steel 76
7.5 Conclusions 76
References 77
8 Experimental Investigation and Optimization of EDM Process Parameters in Machining of Stainless Steel s-32760 Using Taguchi Method 78
8.1 Introduction 78
8.2 Schema of Investigation 80
8.2.1 Design of Experiment, Experimental Setup, and Procedure 81
8.2.2 Result and Analysis 84
8.3 Conclusion 88
References 88
9 By-Pass Flow Meter for Sloped Pipelines 90
9.1 Introduction 90
9.2 Principles of By-Pass Flow Meter 91
9.3 Experimental Investigations 92
9.3.1 Test Circuit 92
9.3.2 Instrumentation 93
9.3.3 Research Studies 93
9.4 Results and Discussions 95
9.5 Conclusions 99
References 99
10 Natural Convection Heat Transfer from Circular Finned Helical Coil Heat Exchanger in Air 100
10.1 Introduction 101
10.2 Materials and Methods 102
10.3 Experimental Set-up and Procedure 103
10.4 Analysis of Experiment 104
10.5 Results and Discussion 105
10.6 Conclusion 107
References 107
11 An Investigation of Responsiveness Impact on Productivity Improvement in Indian MSME 108
11.1 Introduction 108
11.2 Methodology 110
11.2.1 Data Reliability Test 111
11.2.2 Descriptive Analysis 112
11.3 Conclusion 114
References 116
12 Influence of Process Parameters on Weld Bead Geometry and Mechanical Properties in GTAW 117
12.1 Introduction 117
12.2 Literature Review 118
12.3 Experimentation 118
12.3.1 Experiment Procedure 119
12.4 Results and Analysis 120
12.4.1 Analysis of Bead Width 120
12.5 Conclusion 121
Bibliography 123
13 Supplier Selection Using Fuzzy-AHP: A Case Study 124
13.1 Introduction 124
13.2 Integrated Model 126
13.2.1 Fuzzy-Ahp Model 127
13.3 Supplier Selection Through Fuzzy-AHP with Extension Analysis 129
13.4 Results and Discussion 131
References 131
14 Friction Stir Welding of AA 8011: Mechanical and Microstructure Behavior 133
14.1 Introduction 134
14.2 Experimental Procedure 135
14.2.1 Joint Fabrication 135
14.2.2 Determining the Working Levels 136
14.2.3 Testing of the Response Variables 136
14.3 Results and Discussion 137
14.3.1 Tensile Testing 137
14.3.2 Microstructure 139
14.3.3 Microhardness 140
14.4 Conclusion and Future Scope 140
References 141
15 Study the Effects of Input Process Parameters in V-Bending Die on Springback/Go for Different Aluminium Alloys Using Taguchi Approach 143
15.1 Introduction 144
15.2 Research Methodology 145
15.2.1 Materials and Method 145
15.2.2 Design of Experiment and Process Parameters Used for Study 146
15.2.3 Fabrication of V-Bending Die and Trial on a Hydraulic Press 146
15.3 Results and Discussion 149
15.3.1 For AA6082-T6 150
15.3.2 For AA5083-O 151
15.3.3 For AA5052-H32 152
15.4 ANOVA (Analysis of Variance) Table and Regression Equation for Response 153
15.5 Conclusions 154
References 155
16 Comparative Study of Particulate Erosion Phenomena Between Elbow and Target Tee in Pipe Flow 157
16.1 Introduction 157
16.1.1 Mechanism of Erosion in Pipe Flow 157
16.2 Erosion Phenomena in Pipe Bend 160
16.2.1 Mechanism of Erosion in Pipe Flow 160
16.3 Applicability of Cushion/Target Tee 161
16.3.1 Mechanism of Erosion in Target Tee 161
16.4 Conclusion 162
Bibliography 162